Low density closed cell composite aerogel foam and articles including same

ABSTRACT

A composite foam is provided having silica aerogel particles dispersed in a closed cell polymeric foam. The silica aerogel particles are included in a volume fraction between 2 and 60%, and the composite foam has a thermal conductivity of 40 kW/mK or less and a density of 60 kg/m3 or less. In another embodiment, a composite foam is provided having a perforated closed cell polymeric foam and 2-60% hydrophobic silica aerogel particles by volume with a particle size distribution of 1 to 50 μm, where the composite foam has a thermal conductivity of 30 kW/mK or less, a density of 20-45 kg/m3, and an air permeability of 20-40 cubic feet per minute.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 16/032,708 filed Jul. 11, 208, which claims the benefit of andpriority to prior filed Provisional Application Ser. No. 62/531,058,filed Jul. 11, 2017, the disclosures of which are incorporated herein byreference in their entirety.

FIELD OF THE INVENTION

The present invention is generally related to the field of compositefoam and articles including same such as softgoods articles.

BACKGROUND OF THE INVENTION

Use of aerogels for thermal insulation and the low thermal conductivityof aerogels is well known. Favorable thermally conductive propertiesresult from the very high porosity of aerogel and the small pore size ofaerogel material. Insulation having larger pore sizes, such as foam,batting, wool, and other common thermally insulating materials, has ahigher thermal conductivity than aerogel. However, traditional methodsof producing aerogels are time consuming and expensive. Further, usingpowder aerogel in the form of a blanket is known but is not desirabledue to the extensive dusting which makes installation, handling, formingand shaping particularly difficult, and further raises safety issues.Even with formability issues solved, which may be achieved at highexpense and low capacity, closed cell composite foams are heavy, whichis not ideal for use in many applications, such as personal protectiveequipment (PPE). Additionally, the heavy aerogel material foams can havepoor breathability, i.e., low air permeability. There is a need for lowconductivity insulating materials that are lighter and that overcomeproblems inherent in aerogel powders and composites, such as the expenseof formability of aerogel powder and the lack of flexibility andbreathability of composites, as well as the shedding or dusting ofaerogel particles upon application of mechanical stress.

SUMMARY OF THE INVENTION

Embodiments of the present invention are directed to a low densityclosed cell composite aerogel foam in substrate form comprising silicaaerogel/polymer composites and articles including same such as softgoodsarticles. In an embodiment, a composite foam includes silica aerogelparticles dispersed in a closed cell polymeric foam. The composite foamincludes the silica aerogel particles in a volume fraction between 2 and60%, and has a thermal conductivity of 40 kW/mK or less and a density of60 kg/m³ or less. In another embodiment, a composite foam comprises aperforated closed cell polymeric foam and 2-60% hydrophobic silicaaerogel particles by volume having a particle size distribution of 1 to50 μm, wherein the composite foam has a thermal conductivity of 30 kW/mKor less, a density of 20-45 kg/m³, and an air permeability of 20-40cubic feet per minute.

DETAILED DESCRIPTION

All percent values herein refer to percent by volume unless otherwisespecified. All numerical values provided herein are numbers ofapproximation, with no intent to be strictly limited to the exactnumerical value. The terms “increased thermal resistance” and “decreasedthermal conductivity” are used interchangeably because they are inverseproperties of each other. Micron refers to a micrometer, μm. The d(10)is the particle size at which 10% of the volume distribution ofparticles have a size less than this value. The d(50) is the size of theparticle that 50% of the volume distribution is smaller than and 50% ofthe volume distribution is larger than, i.e., the median particle size.The d(90) is the particle size at which 90% of the volume distributionof particles have a size less than this value.

In accordance with embodiments of the invention, a composite foam isprovided in substrate form, such as sheet form or block form. Ratherthan a viscous composite that is coated onto a substrate, the compositefoam of embodiments of the invention is in a non-viscous, substrateform, which may be used by itself or laminated to another substrate,such as a textile.

The composite foam is created by a mixture of silica aerogel particlesand a foamed polymer matrix that is optionally perforated. By way ofexample and not limitation, a standard foaming process using a blowingagent may be used. Any foaming method, including known or proprietarymethods, may be used. The polymer matrix may have a polyolefin basepolymer such as a polyethylene (PE) base. Other suitable base polymersinclude polyurethane (PU), EVA (ethylene vinyl acetate), nitrilebutadiene rubber, or acrylic. The foam may be ester- or ether-based andmay include aliphatic or aromatic structures. The silica aerogelparticles decrease the thermal conductivity of the composite foamthereby enhancing the ability of the composite foam to insulate moreeffectively. Accordingly, the composite shows improved insulatingproperties (e.g., higher thermal resistance, and conversely, lowerthermal conductivity). Advantageously, the aerogel particles areamorphous silica particles having a porosity of 95% or greater. Theparticles are advantageously hydrophobic, which may include subjectinghydrophilic particles to a surface treatment that renders the compositesubstrate hydrophobic.

The composite foam is low density and closed cell for use in substrateform in various articles such as softgood products including apparel,footwear, camping equipment, and other sporting equipment. Increasedthermal performance provides two primary benefits to the final endproduct or user of such product. First, the increased thermalperformance provides added insulation to the softgood product to providethermal comfort against cold environmental temperatures. Second, theincreased thermal performance provides resistance to contact withsurfaces of extreme environmental temperatures. The composite foam slowsthe heat transfer of the extreme external environment through thesoftgood product and to the user. This provides protection to the user.The composite foam may be included in personal protective equipment(PPE).

The composite foam is closed cell to minimize moisture absorption, andlow density to provide a lightweight composite foam. The closed cellcomposite foam density is 60 kg/m³ or less, and advantageously 50 kg/m³or less, and more advantageously 40 kg/m³ or less (per ASTM D1667). Byway of example, the density may be between 10 kg/m³ and 60 kg/m³,between 15 kg/m³ and 55 kg/m³, between 20 kg/m³ and 45 kg/m³, between 25kg/m³ and 50 kg/m³, or between 30 kg/m³ and 40 kg/m³. On one embodiment,the composite foam is perforated, which provides air permeability andthus breathability. The air permeability is 5-60 cubic feet per minute(CFM), for example 20-40 CFM, and the perforations are advantageouslymicro-perforations of diameter 1 mm or less, for example, 0.3-1 mm.

Aerogel particles can be obtained from any commercial source, includingfor example Cabot Corporation, Svenska Aerogel, and Aspen Aerogel. Byway of example and not limitation, Enova® Aerogel IC3110 from CabotCorporation (particle size 0.1-0.7 mm), Enova® Aerogel IC3100 from CabotCorporation (particle size 2-40 mm), or Quartzene® Z1 from SvenskaAerogel (particle size 1-40 mm) may be used. The aerogel particles mayhave a particle size distribution ranging from 0.1-100 microns, 0.5-70microns, 1-50 microns, 1-30 microns, 1-10 microns, 10-40 microns, 20-30microns, or 30-50 microns. The median particle size may be on the orderof 2-10 microns, 2-7 microns, 4-10 microns, 3-8 microns, or 4-6 microns.In one embodiment, the aerogel particles have a particle sizedistribution of 0.5-50 microns with a d(10) in the range of 1-3 microns,a d(90) in the range of 8-30 microns, and a d(50) in the range of 2-7microns. In one example, the aerogel particles have a particles sizedistribution of 1-40 microns with a d(10) of ˜2 microns, a d(50) of ˜4-6microns, and a d(90) of ˜10-14 microns. The pore size distribution inthe aerogel particles may be on the order of 1-50 nm, and the surfacearea (S_(BET)) may be on the order of 200-350 m²/g. The aerogelparticles may be included in the composite material at a volume fractionfrom 2-60%, 3-40%, 4-30%, 20-60%, 20-40%, 30-50%, or 40-60%.

To ensure chemical compatibility or to ensure the performance of theaerogel additives, the aerogel particles may be treated in some mannerto add physical or chemical functionality. For example, the aerogelparticles may be treated to render the composite substrate hydrophobic,thereby increasing the water resistance of the composite foam. Theaerogel particles may be treated or processed into the base polymer. Inone embodiment, the aerogel particles are physically blended into apolymer matrix and then the mixture is foamed and extruded to form thesubstrate. To prevent silica dust during mixing, a master batch processmay be used in which a slurry is first created with silica aerogelparticles using a solvent, such as isopropyl alcohol. The slurry is thenmixed with a waterborne polymer dispersion. Alternatively, an enclosedvessel may be used for mixing to eliminate the need for first creatingthe silica aerogel slurry.

The polymeric matrix may be an aqueous polyurethane solution but mayalso include polyester, nitrile butadiene and acrylic solutions plustheir solvent-based counterparts. Further, the composite formulation mayinclude one or more blowing agents. Any commercially available polymericmatrix material may be used. Additionally, any known blowing agent maybe used. The polymeric matrix may be foamed prior to adding the aerogelparticles, or after adding the aerogel particles.

The composite foam may optionally include flame inhibiting chemicals foruse in PPE or other articles that may be exposed to extreme heatconditions such as from fire or explosives. Such articles may be used byfirefighters or other first responders, military personnel, or forcamping equipment such as tents for protection from forest fires or userflame sources.

The composite foam may optionally include anti-microbial agents toimpart anti-microbial performance to an article incorporating thecomposite foam layer. For example, the anti-microbial agent may preventthe foam from growing or propagating microbes from human contact. Inanother example, the anti-microbial agent may kill microbes and preventtheir spread.

The thermal performance of the composite foam is determined by measuringthe thermal conductivity or thermal resistance using a variety ofmethodologies. Performance gains are compared against a polymeric foamlayer without the addition of aerogel particles in the foam layer.Effective thermal performance gains may be at least 20%, or at least30%, or at least 40%, or at least 50% greater than the referencematerial. For example, the addition of aerogel particles may beeffective to decrease thermal conductivity of the composite foam by atleast 30% compared to the foamed polymer. According to an embodiment, acomposite foam layer exhibits a thermal conductivity of 40 kW/mK orless, such as 35 kW/mK or less, or 30 kW/mK or less (per ASTM C518 @0.3psi).

The composite foam is closed cell to minimize moisture absorption forwearing apparel and personal equipment. In an embodiment, thehydrophobicity of the composite foam is enhanced by treating the silicaaerogel particles for hydrophobicity making the foam water-resistant asmeasured by water absorption of less than 0.1% by volume, from 0.01 to0.1 by volume, from 0.025 to 0.075 by volume, or from 0.01 to 0.05 byvolume (per ASTM D1171). The treatment may be a chemical treatment toincrease the hydrophobicity such as a treatment with one or morefluorinated compounds.

The composite foam is provided in substrate form, such as sheet form orblock form. Rather than a viscous composite that is coated onto asubstrate, the composite foam disclosed herein is in a non-viscous,substrate form, which may be used by itself or laminated to anothersubstrate, such as a textile. To that end, the composite foam may beextruded in blocks or sheets and may be skived to a final thickness. Theaverage thickness may be greater than 0.5 mm, and advantageously 1.5 mmor greater. Further, the average thickness may be less than 10 mm, andadvantageously 6 mm or less. By way of example and not limitation, theaverage thickness may be from 1.5 to 6 mm, 1.5 to 4 mm, or 2 to 3 mm.

In an embodiment, the composite foam is perforated to add airpermeability and moisture vapor permeability. Air and moisture vaporpermeability may be advantageous in some applications, such as apparel.To maintain the thermal insulation, the perforations may be microperforations with a diameter of 1 mm or less, or between 0.3 mm and 1mm. The perforations are advantageously incorporated in a size andamount effective to provide air permeability of 5-60 cubic feet perminute (CFM), for example 20-40 CFM (per ASTM D737). Below 5 CFM, thecomposite foam is not considered breathable, and above 60 CFM, thecomposite foam becomes too air permeable, which can dramaticallydecrease thermal performance.

In an embodiment, the composite foam, in substrate form, may belaminated on the face and/or back surfaces with a textile for thepurpose of, for example, increased mechanical strength, moisturemanagement, softness or wearing comfort, and environmental protection(e.g., wind and water resistance). For example, a sheet of compositefoam may be laminated to a textile to line the interior surface or theexterior surface or both of the textile to protect the wearer of thearticle of clothing from wind, rain, and/or cold temperatures. Inanother example, a block of composite foam may be laminated to theunderside of a shoe lining to provide cushioning comfort, waterresistance and frost-bite protection. In other examples, sheets orblocks of composite foam may line the fabric of tents, sleeping bags,backpacks, soft coolers, boots, ear muffs, etc. Laminating the compositefoam to a textile simplifies processing and manufacturing, for example,cutting and sewing the material, and also provides additional strengthat seams. That being said, it is contemplated that the low densityclosed cell composite foams discloses herein may be useful in substrateform as the article itself without the need for lamination to anothersubstrate.

The combination of thermal efficiency, low density, low moistureabsorption (via closed cell and hydrophobic aerogel particles) andoption for air permeability provide for an ideal insulating material inwearing apparel and personal equipment.

This has been a description of embodiments of the present inventionalong with the various methods of practicing the present invention.However, the invention itself should only be defined by the appendedclaims.

What is claimed is:
 1. A composite foam comprising: silica aerogelparticles dispersed in a closed cell polymeric foam, wherein thecomposite foam includes the silica aerogel particles in a volumefraction between 2 and 60%, and has a thermal conductivity of 40 kW/mKor less and a density of 60 kg/m³ or less.
 2. The composite foam ofclaim 1, wherein the density is 50 kg/m³ or less.
 3. The composite foamof claim 1, wherein the density is 20-45 kg/m³.
 4. The composite foam ofclaim 1, wherein the density is 30-40 kg/m³.
 5. The composite foam ofclaim 1, wherein the thermal conductivity is 30 kW/mK or less.
 6. Thecomposite foam of claim 1, wherein the silica aerogel particles arehydrophobic.
 7. The composite foam of claim 6, wherein a waterabsorption of the composite foam is 0.1% by volume or less.
 8. Thecomposite foam of claim 1, wherein the composite foam has an averagethickness between 1.5 to 6 mm.
 9. The composite foam of claim 1, whereinthe composite foam includes perforations having a diameter of 1 mm orless.
 10. The composite foam of claim 1, wherein the silica aerogelparticles are included in a volume fraction from 3-40%.
 11. Thecomposite foam of claim 1, wherein the silica aerogel particles have aparticle size distribution of 0.1-100 microns.
 12. The composite foam ofclaim 1, wherein the silica aerogel particles have a particle sizedistribution of 0.5-70 microns.
 13. The composite foam of claim 1,wherein the silica aerogel particles have a particle size distributionof 1-50 microns.
 14. The composite foam of claim 1, wherein the silicaaerogel particles have a median particle size of 2-10 microns.
 15. Thecomposite foam of claim 1, further comprising a flame inhibitingchemical.
 16. The composite foam of claim 1, further comprising ananti-microbial agent.
 17. The composite foam of claim 1, wherein thecomposite foam has a face surface and a back surface, the composite foamfurther comprising: a textile laminated on at least one of the facesurface or the back surface.
 18. A composite foam comprising: aperforated closed cell polymeric foam; and 2-60% hydrophobic silicaaerogel particles by volume having a particle size distribution of 1 to50 μm, wherein the composite foam has a thermal conductivity of 30 kW/mKor less, a density of 20-45 kg/m³, and an air permeability of 20-40cubic feet per minute.
 19. The composite foam of claim 20, wherein awater absorption of the composite foam is 0.1% by volume or less. 20.The composite foam of claim 20, wherein the composite foam has anaverage thickness between 1.5 to 6 mm.
 21. The composite foam of claim20, wherein the perforated closed cell polymeric foam includesperforations having a diameter of 1 mm or less.
 22. The composite foamof claim 20, wherein the composite foam has a face surface and a backsurface, the composite foam further comprising: a textile laminated onat least one of the face surface or the back surface.